Modular solar panel design for improved durability &amp; repairability

ABSTRACT

A modular solar panel including multiple solar panel modules. Each solar panel module includes multiple solar cell assemblies. Each solar cell assembly includes a protective glass, a base plate, a solar cell array located therebetween, and an electrical connection ribbons extending from the ends of the solar cell array. The solar panel module further includes multiple coupling modules. Each coupling module includes an interior cavity to receive one end of the solar cell assembly, a pin joint located on exterior of a first coupling module to interlock with a pin joint located on exterior of a second coupling module, and an electrical connection plug to receive one of the first and the second electrical connection ribbons. The electrical connection plug of the first coupling module electrically connects with an electrical connection plug of the second coupling module.

STATEMENT REGARDING PRIOR DISCLOSURE BY THE INVENTORS

Aspects of this technology are described in an article “Fundamentalstudy related to the development of modular solar panel for improveddurability and repairability” published in IET Renewable PowerGeneration, Oct. 28, 2020, which is incorporated herein by reference inits entirety.

BACKGROUND Technical Field

The present disclosure is directed to a modular solar panel design forimproved durability and repairability and a method of assembling themodular solar panel.

Description of Related Art

The “background” description provided herein is for the purpose ofgenerally presenting the context of the disclosure. Work of thepresently named inventors, to the extent it is described in thisbackground section, as well as aspects of the description which may nototherwise qualify as prior art at the time of filing, are neitherexpressly or impliedly admitted as prior art against the presentinvention.

With an increase in need for renewable energy sources, harvestingelectrical power from solar energy is being widely practiced due to vastabundance, free availability, and ease of use. Typically, solar powergeneration involves installing large solar panels on rooftops orterraces of buildings. The solar panels absorb solar radiation andconvert the absorbed energy into electricity which can be used to powermultiple applications. However, to address the high demand ofelectricity, large sized, multiple solar panels may need to be used andinstallation of such solar panels can be complex and difficult.Generally, a mounting system is used to secure the solar panels, whereeach solar panel is rigidly affixed to neighboring solar panels. In suchan arrangement, it is important to retain alignment of each solar panelwith the neighboring solar panels to ensure the electrical connectionsare completed.

U.S. Patent Application Publication No. 2015/0311371 provides modular,expandable, and interconnectable solar photovoltaic appliances that canbe connected to each other and other derivative products in multipleseries and parallel configurations to supply a specific amount ofelectrical power to an application requiring electrical energy. However,the photovoltaic appliances are connected to each other using applianceconnectors which include male connectors and female connectors made ofsheet metal strips. Such appliance connectors render an assembly processof the photovoltaic appliances complex.

U.S. Patent Application Publication No. 2016/0087578 describes a designfor solar panel that allows for modular installation and efficientremoval of panels irrespective of the panel's relative location in anarray arrangement. Multiple panels are mechanically coupled usingmultiple splices to form the array arrangement. The presence of suchmultiple splices adds to the complexity of the overall installation ofthe panels.

Each of the aforementioned patent reference suffers from one or moredrawbacks hindering their adoption. For example, the design of modularsolar panels described by the references renders the system complex andless cost effective. Accordingly, it is one object of the presentdisclosure to provide methods and systems for achieving improveddurability and repairability of the modular solar panels which areeasily installed and in which a single unit can be easily replaced.

SUMMARY

In an exemplary embodiment, a modular solar panel is described. Themodular solar panel includes a plurality of solar panel modules. Eachsolar panel module includes a plurality of solar cell assemblies. Eachsolar cell assembly includes a protective glass, a base plate, a solarcell array located between the protective glass and the base plate, anda first electrical connection ribbon and a second electrical connectionribbon extending from a first end and a second end of the solar cellarray. The solar panel module further includes a plurality of couplingmodules. Each coupling module includes an interior cavity configured toreceive an end of the solar cell assembly, a pin joint located on anexterior of the coupling module, where the pin joint of a first couplingmodule is configured to interlock with the pin joint of a secondcoupling module. Each coupling module also includes an electricalconnection port configured to receive one of the first and the secondelectrical connection ribbons. The electrical connection port of thefirst coupling module is configured to electrically connect to theelectrical connection port of the second coupling module.

In another exemplary embodiment, a method for assembling a modular solarpanel is described. The method includes forming a first solar panelmodule by forming a first solar cell assembly by sandwiching a firstsolar cell array between a first protective glass and a first baseplate, so that a first electrical connection ribbon extends from a firstend of the first solar cell array and a second connection ribbon extendsfrom a second end of the first solar cell array, the second end anopposite end to the first end of the first solar cell array. The methodfurther includes joining a first rectangular upper component to a firstrectangular lower component to form a first coupling module having afirst interior cavity, a first electrical connection port, a firstelectrical connection socket and a first pin joint having two pins andone notch. The method further includes joining a second rectangularupper component to a second rectangular lower component to form a secondcoupling module having a second interior cavity, a second electricalconnection port, a second electrical connection socket and a second pinjoint having one pin and two notches. The method further includesinserting the first end of the first solar cell assembly into the firstinterior cavity of the first coupling module while guiding the firstelectrical connection ribbon into the first electrical connection portand inserting the second end of the first solar cell assembly into thesecond interior cavity of the second coupling module while guiding thesecond electrical connection ribbon into the second electricalconnection socket.

In another exemplary embodiment, a method for assembling a modular solarpanel is described. The method includes forming a plurality of solarpanel modules, by forming a plurality of solar cell assemblies. Themethod further includes forming a plurality of coupling modules, eachcoupling module including an electrical plug at a first end, anelectrical socket at a second end, a pin joint, a first magnet having afirst polarity located between the electrical plug and the pin joint, asecond magnet having a second polarity located between the electricalsocket and the pin joint, and an interior cavity. The method furtherincludes inserting a first end of each of the solar cell assemblies intoa first coupling module having a pin joint configuration including twopins and a notch. The method further includes inserting a second end ofeach of the solar cell assemblies into a second coupling module having apin joint configuration including one pin and two notches. The methodfurther includes joining a first solar panel module of the plurality ofsolar panel modules to a second solar panel module of the plurality ofsolar panel modules by interlocking the two pins and the notch of thefirst solar panel module into the one pin and two notches of the secondsolar panel module, and inserting the electrical plug of the first solarpanel module into the electrical socket of the second solar panelmodule, while magnetically aligning the first solar panel module withthe second solar panel module.

The foregoing general description of the illustrative embodiments andthe following detailed description thereof are merely exemplary aspectsof the teachings of this disclosure and are not restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of this disclosure and many of theattendant advantages thereof will be readily obtained as the samebecomes better understood by reference to the following detaileddescription when considered in connection with the accompanyingdrawings, wherein:

FIG. 1 is an exploded view of a modular solar panel, according tocertain embodiments of the present disclosure;

FIG. 2A is an enlarged view of a portion ‘A’ in FIG. 1 showing aperspective view of two interconnected solar panel modules of themodular solar panel, according to certain embodiments of the presentdisclosure.

FIG. 2B is a perspective view of the two solar panel modulesdisconnected from one another, according to certain embodiments of thepresent disclosure;

FIG. 3 is an exploded view of a solar panel module, according to certainembodiments of the present disclosure;

FIG. 4A is a perspective view of a first rectangular upper component ofa first coupling module of the solar panel module of FIG. 3, accordingto certain embodiments of the present disclosure;

FIG. 4B is an exploded view of a first rectangular lower component ofthe first coupling module of FIG. 3, according to certain embodiments ofthe present disclosure;

FIG. 5A is a perspective view of a second rectangular upper component ofa second coupling module of the solar panel module of FIG. 3, accordingto certain embodiments of the present disclosure;

FIG. 5B illustrates an exploded view a second rectangular lowercomponent of the second coupling module of FIG. 3, according to certainembodiments of the present disclosure;

FIG. 5C depicts alignment of the two interconnected solar panel modules,according to certain embodiments of the present disclosure;

FIG. 6A is a flowchart of a method for assembling the modular solarpanel and forming a first solar panel module, according to certainembodiments of the present disclosure;

FIG. 6B is a flowchart of the method for assembling the modular solarpanel and forming a second solar panel module, according to certainembodiments of the present disclosure; and

FIG. 6C is a flowchart of a method for assembling the modular solarpanel with the first solar panel module and the second solar panelmodule, according to certain embodiments of the present disclosure.

DETAILED DESCRIPTION

In the drawings, like reference numerals designate identical orcorresponding parts throughout the several views. Further, as usedherein, the words “a,” “an” and the like generally carry a meaning of“one or more,” unless stated otherwise.

Furthermore, the terms “approximately,” “approximate,” “about,” andsimilar terms generally refer to ranges that include the identifiedvalue within a margin of 20%, 10%, or preferably 5%, and any valuestherebetween.

Certain terms used in the present disclosure are for the purpose ofreference only and are not intended to be limiting. For example, termssuch as “upper”, “lower”, “above”, and “below” refer to directions inthe drawings to which reference is made. Terms such as “front”, “back”,“rear”, “side”, “outboard”, and “inboard” describe the orientationand/or location of portions of the component within a consistent butarbitrary frame of reference which is made clear by reference to thetext and the associated drawings describing the component underdiscussion. Such terminology may include the words specificallymentioned above, derivatives thereof, and words of similar import.

Aspects of the present disclosure are directed to a modular solar panelassembly and method for assembling the modular solar panel. Design andconstruction of the modular solar panel of the present disclosure aidsin reducing time required to assemble individual solar panel modules toachieve the modular solar panel assembly. Referring to FIG. 1, anexploded view of a modular solar panel 100 is illustrated. According toan exemplary embodiment, the module solar panel 100 includes a pluralityof solar panel modules 102-1, 102-2, 102-3 . . . , 102-N (hereinafterreferred to as “the solar panel module(s) 102”) disposed along multiplerows and columns to constitute an array of solar panels modules. As canbe seen in FIG. 1, a first column 104 of the solar panel modules 102includes a first solar panel module 102-1, a second solar panel module102-2 electrically coupled to the first solar panel module 102-1, and athird solar panel module 102-3 electrically coupled to the second solarpanel module 102-2. Similarly, a second column 106 of the solar panelmodules 102 and a third column 108 of the solar panel modules 102 aredisposed in adjacent order to the first column 104 to constitute themodular solar panel 100. In an embodiment, electrical leads from eachcolumn may be combined at a single point to realize electrical powerharvested by the modular solar panel 100. In another embodiment, eachcolumn may be electrically connected in series to an adjacent column,such that one electrical lead wire may extend from one end of themodular solar panel 100 and another electrical lead wire may extend froma diagonally opposite end of the modular solar panel 100 to realizeelectrical power harvested by the modular solar panel 100.

FIG. 1 also illustrates a frame 110 made of rigid material, such as, forexample, steel, rigid plastic, aluminum or cast iron. The frame 110includes a body 112, horizontal ribs 114 extending between a first pairof opposite peripheries of the body 112, and vertical ribs 116 extendingbetween a second pair of opposite peripheries of the body 112. Adistance between two adjacent horizontal ribs 114 is substantially equalto a length “L” of a solar panel module 102 and a distance between twoadjacent vertical ribs 116 is substantially equal to a width “W” of thesolar panel module 102. With such configuration of the frame 110, thehorizontal ribs 114 are configured to provide support to the solar panelmodules 102 at a portion where one solar panel module 102 electricallyconnects with an adjacent solar panel module 102. Similarly, thevertical ribs 116 are configured to provide support to the solar panelmodules 102 at a portion where one solar panel module 102 of the firstcolumn 104 abuts an adjacent solar panel module 102 of the adjacentcolumn, such as the second column 106. As such, the horizontal ribs 114and the vertical ribs 116 prevent sagging of the solar panel modules 102at the portions of connections with adjacent solar panel modules 102,thereby eliminating the possibility of disconnection between the solarpanel modules 102. In some embodiments, the solar panel modules 102mounted on the frame 110 may together constitute the modular solar panel100. The number of solar panel modules 102 shown in FIG. 1 is only forpurpose of illustration and brevity and should not be considered aslimiting. Any number of solar panel modules 102 may be used to form themodular solar panel 100. According to some implementations, the modularsolar panel 100 may be located in a solar farm or mounted on a buildingterrace to harvest the solar energy.

FIG. 2A is an enlarged view of a portion ‘A’ in FIG. 1 in which aperspective view of two interconnected solar panel modules 102 is shown,such as the first solar panel module 102-1 and the second solar panelmodule 102-2. According to an exemplary embodiment, each solar panelmodule 102 includes a solar cell assembly 200 having a protective glass202, a base plate 204 aligned and located beneath the protective glass202, and a solar cell array 206 located between the protective glass 202and the base plate 204. In some embodiments, the protective glass 202may be transparent to absorb the incident solar radiation and the baseplate 204 may be constructed of any one of plastic and syntheticpolymer. As used herein, the term “solar cell array” refers to multiplecolumns of solar cells located along the length of the solar panelmodule 102. Each solar panel module 102 includes a plurality of couplingmodules (208, 210, 212, 214) which aid in interlocking the first solarpanel module 102-1 with the second solar panel module 102-2.

FIG. 2B illustrates a perspective view of the first solar panel module102-1 disconnected from the second solar panel module 102-2. The firstsolar panel module 102-1 includes a first coupling module 208 and asecond coupling module 210, and the second solar panel 102-2 includes athird coupling module 212 and a fourth coupling module 214. According toan exemplary embodiment, each coupling module includes a pin jointlocated on an exterior thereof. For example, in the first solar panelmodule 102-1, the first coupling module 208 includes a first pin joint216 (alternatively referred to as “a first pin joint configuration”) andthe second coupling module 210 includes a second pin joint 218(alternatively referred to as “a second pin joint configuration”).Similarly, in the second solar panel 102-2, the third coupling module212 includes a third pin joint 220 and the fourth coupling module 214includes a fourth pin joint 222. In such arrangement, the first pinjoint 220 of the third coupling module 212 of the second solar panelmodule 102-2 is configured to interlock with the second pin joint 218 ofthe second coupling module 210 of the first solar panel 102-1.

FIG. 3 illustrates an exploded view of the first solar panel module102-1. FIG. 3 will be described in conjunction with FIG. 1 to FIG. 2B.To this end, it will be understood that each solar panel module 102 isidentical in construction with respect to the adjacent solar panelmodules 102. According to an exemplary embodiment, each coupling moduledefines an interior cavity configured to receive an end of the solarcell assembly 200. The first coupling module 208 defines a first cavity302 configured to receive a first end 304 of the solar cell assembly 200and the second coupling module 210 defines a second cavity 306configured to receive a second end 308 of the solar cell assembly 200.

According to an exemplary embodiment, the solar cell assembly 200includes a first set of conducting leads lines 310 extending along thelength “L” of the first solar panel module 102-1. The solar cellassembly 200 also includes a second set of conducting lead lines 312located at the first end 304 and the second end 308 of the solar cellassembly 200 and extending in a direction perpendicular to the length“L” thereof. In some embodiments, the first set of conducting leadslines 310 and the second set of conducting lead lines 312 may be madeof, but not limited to, aluminum or copper. Further, the solar cellassembly 200 includes a first electrical connection ribbon 314 extendingfrom a first end 316 of the solar cell array 206 and a second electricalconnection ribbon 318 extending from a second end 320 of the solar cellarray 206. The first electrical connection ribbon 314 and the secondelectrical connection ribbon 318 aid in drawing the harvested solarpower from the solar cell assembly 200. According to an exemplaryembodiment, the first set of conducting leads lines 310 and the secondset of conducting lead lines 312 constitute a metal interconnect layer322 configured to electrically connect the plurality of rows of solarcells (or referred to as “the solar cell array 206”) in a series and ina parallel circuit having an input at the first electrical connectionribbon 314 and an output at the second electrical connection ribbon 318.

FIG. 4A and FIG. 4B illustrate components of the first coupling module208. According to an exemplary embodiment, the first coupling module 208is constituted by removably coupling two individual components.Particularly, FIG. 4A illustrates a perspective view of a firstrectangular upper component 402 of the first coupling module 208 andFIG. 4B illustrates a perspective view of a first rectangular lowercomponent 404 of the first coupling module 208.

The first rectangular upper component 402 includes a first perimeter“P1”, a first planar surface 406, a first upper sidewall 408, a secondupper sidewall 410, and an upper front wall 412 having a first thickness“T1”. The first upper sidewall 408, the second upper sidewall 410 andthe upper front wall 412 extend perpendicularly along a first height“H1” of the first rectangular upper component 402 from the first planarsurface 406 at the first perimeter “P1”. According to an exemplaryembodiment, the first rectangular upper component 402 also includes atleast one upper protrusion 414 and at least one upper cut out 416centrally located on an exterior of the upper front wall 412. Each ofthe at least one upper protrusion 414 and at least one upper cut out 416extends in a direction of the first thickness “T1” of the firstrectangular upper component 402.

The first rectangular upper component 402 defines a first slot 430extending along a portion of a first width “W1” thereof. The firstrectangular upper component 402 also defines a first upper pocket 434and a second upper pocket 436 located at either side of the at least oneupper protrusion 414 and at least one upper cut out 416. Each of thefirst upper pocket 434 and the second upper pocket 436 are identical andare defined along the first height “H1”, such that a depth of eachpocket 434, 436 is less than first height “H1” of the first rectangularupper component 402. For example, a cut-section C1-C1′ shows that adepth “M1” of the second upper pocket 436 is less than the first height“H1” as shown in FIG. 4A.

Referring to FIG. 4B, the first rectangular lower component 404 includesa second perimeter “P2”, a second planar surface 418, a first lowersidewall 420, a second lower sidewall 422, and a lower front wall 424having a second thickness equal to the first thickness “T1”. As such,the second thickness is also referenced as “T1” in the figures and thedescription. The first lower sidewall 420, the second lower sidewall422, and the lower front wall 424 extend perpendicularly along a secondheight “H2” of the first rectangular lower component 404 from the secondplanar surface 418 at the second perimeter “P2”. The first rectangularlower component 404 also includes at least one lower protrusion 426 andat least one lower cut out 428 centrally located on an exterior of thelower front wall 424. Each of the at least one lower protrusion 426 andat least one lower cut out 428 extends in a direction of the secondthickness “T1” of the first rectangular lower component 404.

The first rectangular lower component 404 of FIG. 4B defines a secondslot 432 extending along a portion of a second width “W2” thereof. Thefirst rectangular lower component 404 also defines a first lower pocket438 and a second lower pocket 440 to either side of the at least onelower protrusion 426 and at least one lower cut out 428. Each of thefirst lower pocket 438 and the second lower pocket 440 are identical andare defined along the second height “H2”, such that a depth of eachpocket 438, 440 is less than second height “H2” of the first rectangularlower component 404. For example, a cut-section C2-C2′ shows that adepth “M2” of the second lower pocket 440 is less than the second height“H2” as shown in FIG. 4B. In some embodiments, each of the first upperpocket 434, the second upper pocket 436, the first lower pocket 438, andthe second lower pocket 440 may be located in a range, but not limitedto, of about 0.1 cm to about 0.5 cm from respective exterior surfaces ofthe respective coupling modules. According to an exemplary embodiment,each of the first upper pocket 434, the second upper pocket 436, thefirst lower pocket 438, and the second lower pocket 440 has equal width,equal depth and equal height.

The first rectangular upper component 402 is configured to removablycouple with the first rectangular lower component 404. For the purposeof such coupling, the first rectangular upper component 402 may bealigned with the first rectangular lower component 404, such that therespective sidewalls and the respective front walls are aligned witheach other. In an embodiment, the first thickness “T1” of the firstrectangular upper component 402 may be equal to the second thickness“T1” of the first rectangular lower component 404, so that therespective sidewalls and the respective front walls define uniformsurfaces at respective sides when the first rectangular upper component402 is coupled with the first rectangular lower component 404.

In the coupled state, the at least one upper protrusion 414 aligns withthe at least one lower protrusion 426 to define a first pin 342 (seeFIG. 3). Similarly, the at least one upper cut out 416 aligns with theat least one lower cut out 428 to define notch 344 (see FIG. 3). Asillustrated in FIG. 4A and FIG. 4B, the first rectangular uppercomponent 402 defines one upper protrusion 414 and two cut outs 416. Thefirst rectangular lower component 404 defines one lower protrusion 426and two cut outs 428. In the coupled state, the upper protrusion 414 andthe lower protrusion 426 together forms a pin structure to define thefirst pin 342. Similarly, a first upper cut out 416-1 aligns with afirst lower cutout 428-1 to define a first notch 344-1 and a secondupper cut out 416-2 aligns with a second lower cut out 428-2 to define asecond notch 344-2 as shown in FIG. 3. The first pin 342, the firstnotch 344-1, and the second notch 344-2 together define the first pinjoint 216 of the third coupling module 212. Additionally, in the coupledstate, the first upper pocket 434 aligns with the first lower pocket 438and the second upper pocket 436 aligns with the second lower pocket 440.

Further, the first coupling module 208 includes a first magnet 446 and asecond magnet 448. Each of the first magnet 446 and a second magnet 448has a magnet width equal to the pocket width, a magnet thickness equalto the pocket breadth and a magnet height equal to twice the pocketdepth. As used herein, the term “pocket width” refers to a dimensionconsidered along the width of the first coupling module 208, the term“pocket breadth” refers to a dimension considered in a directionperpendicular to the width of the first coupling module 208, and theterm “pocket depth” refers a dimension considered along respective frontwalls.

Owing to such dimensions of the magnets and the pockets, the firstmagnet 446 is configured to be rigidly inserted into the first lowerpocket 438 such that a portion of the first magnet 446 lies outside thefirst lower pocket 438, and the second magnet 448 is configured to berigidly inserted into the second lower pocket 440 such that a portion ofthe second magnet 448 lies outside the second lower pocket 440. Theportion of the first magnet 446 extending outside the first lower pocket438 is configured to be received within the first upper pocket 434 andthe portion of the second magnet 448 extending outside the second lowerpocket 440 is configured to be received within the second upper pocket436, when the first rectangular upper component 402 is coupled to thefirst rectangular lower component 404. Such arrangement of the magnetsand the pockets holds the first rectangular upper component 402 and thefirst rectangular lower component 404 together.

In some embodiments, the first lower pocket 438 may be defined for alarger width along the width “W2” of the first rectangular lowercomponent 404 and accordingly length of the first magnet 446 may beincreased to completely occupy the first lower pocket 438. In someembodiments, the second lower pocket 440 and the second magnet 448 mayalso extend for greater width along the width “W2” of the firstrectangular lower component 404. In some embodiments, the second planarsurface 418 may include multiple magnets in form of pellets locatedalong the width “W2” of the first rectangular lower component 404. Insome embodiments, a surface of the first rectangular upper component 402configured to abut with the second planar surface 418 may include ametal strip to magnetically couple with the first magnet 446 and thesecond magnet 448, thereby securing the first rectangular uppercomponent 402 with the first rectangular lower component 404 in thecoupled state. In an alternative embodiment, the magnet may be lined onall but its front facing side with steel, carbon steel or iron to form akeeper to increase the strength of the magnetic field as seen at thefront face of the coupling module 208.

Further, in the coupled state, the first slot 430 and the second slot432 together define the first cavity 302 (also referred to as the firstinterior cavity in the present disclosure) configured to removablyreceive the first end 304 of the solar cell assembly 200. In someembodiments, the first cavity 302 may be configured to receive firstends of two solar cell assemblies. In such arrangement, the width of thefirst coupling module 208 may be increased to accommodate two solar cellassemblies.

In an embodiment, each of the first magnet 446 and the second magnet 448may be neodymium magnet. In an embodiment, the first magnet 446 may havea positive polarity and the second magnet 448 may have a negativepolarity with respect to the upper front wall 412 of the first couplingmodule 208.

According to an exemplary embodiment, the first rectangular lowercomponent 404 includes a first lower socket casing 450 located betweenthe first lower pocket 438 and a first edge 452 of the first rectangularlower component 404, where the first edge 452 extends in the directionof the second thickness “T1”. The first lower socket casing 450 isdefined by an indentation in the lower front wall 424, where theindentation has a first depth “D1”. In an embodiment, the first lowersocket casing 450 defines an opening (not shown) configured to receivean electrical connection ribbon of an adjacent solar panel module 102. Aribbon in a socket of a first modular solar cell assembly iselectrically connected to a ribbon in a plug of a second modular solarcell assembly by using notch and magnetic field compression. The firstrectangular lower component 404 also includes a first lower plug casing454 located between the second lower pocket 440 and a second edge 456 ofthe first rectangular lower component 404. The second edge 456 isparallel to the first edge 452 and the first lower plug casing 454extends for a first length “L1” from the lower front wall 424 in thedirection of the second thickness “T1”. In an embodiment, the firstdepth “D1” of the first lower socket casing 450 is equal to the firstlength “L1” of the first lower plug casing 454.

FIG. 5A and FIG. 5B illustrate components of the second coupling module210. The second coupling module 210 is constituted by removably couplingtwo individual components. FIG. 5A illustrates a perspective top view ofa second rectangular upper component 502 of the second coupling module210 and FIG. 5B illustrates a perspective view of a second rectangularlower component 504 of the second coupling module 210.

The second rectangular upper component 502 includes a third perimeter“P3”, a third planar surface 506, a first upper sidewall 508, a secondupper sidewall 510, and an upper front wall 512 having a third thickness“T3”. The first upper sidewall 508, the second upper sidewall 510 andthe upper front wall 512 extend perpendicularly along a third height“H3” of the second rectangular upper component 502 from the third planarsurface 506 at the third perimeter “P3”. According to an exemplaryembodiment, the second rectangular upper component 502 also includes afirst upper protrusion 514 and a second upper protrusion 516 centrallylocated on an exterior of the upper front wall 512. Each of the firstupper protrusion 514 and a second upper protrusion 516 extends in adirection of the third thickness “T3”. The second rectangular uppercomponent 502 also defines an upper cut out 518 centrally located on theexterior of the upper front wall 512. Particularly, the upper cut out518 is located in between the first upper protrusion 514 and the secondupper protrusion 516. In an embodiment, the first upper protrusion 514and the second upper protrusion 516 may be symmetrical about the uppercut out 518. In some embodiments, the first upper protrusion 514 and thesecond upper protrusion 516 may be located distant from each other. Insome embodiments, the second rectangular upper component 502 may includemultiple protrusions and multiple cut outs to add to the stability ofthe interlocking between the solar panel modules 102.

Additionally, the second rectangular upper component 502 defines a thirdslot 520 extending along a portion of a third width “W3” thereof; and afirst upper pocket 522 and a second upper pocket 524 located on eitherside of the protrusions 514, 516 and the upper cut out 518. Each of thefirst upper pocket 522 and the second upper pocket 524 are identical andare defined along the third height “H3”, such that a depth of eachpocket 522, 524 is less than third height “H3” of the second rectangularupper component 502. For example, a cut-section ‘C3-C3’ shows that adepth “M3” of the second upper pocket 524 is less than the third height“H3” as shown in FIG. 5A.

Referring to FIG. 5B, the second rectangular lower component 504includes a fourth perimeter “P4”, a fourth planar surface 526, a firstlower sidewall 528, a second lower sidewall 530, and a lower front wall532 having a fourth thickness equal to the third thickness “T3”. Assuch, the fourth thickness is also referenced as “T3” in the figures andthe description. The first lower sidewall 528, the second lower sidewall530 and the lower front wall 532 extend perpendicularly along a fourthheight “H4” of the second rectangular lower component 504 from thefourth planar surface 526 at the fourth perimeter “P4”. The secondrectangular lower component 504 also includes a first lower protrusion534 and a second lower protrusion 536 centrally located on an exteriorof the lower front wall 532. Each of the first lower protrusion 534 anda second upper protrusion 536 extends in a direction of the fourththickness “T3”. The second rectangular lower component 504 also definesa lower cut out 538 centrally located on the exterior of the lower frontwall 532. Particularly, the lower cut out 538 is located in between thefirst lower protrusion 534 and the second lower protrusion 536.

Additionally, the second rectangular lower component 504 defines afourth slot 540 extending along a portion of a fourth width “W4”thereof; and a first lower pocket 542 and a second lower pocket 544located on either side of the protrusions 534, 536 and the lower cut out538. Each of the first lower pocket 542 and the second lower pocket 544are identical and are defined along the fourth height “H4”, such that adepth of each pocket 542, 544 is less than fourth height “H4” of thesecond rectangular lower component 504. For example, a cut-section‘C4-C4’ shows that a depth “M4” of the second lower pocket 544 is lessthan the third height “H4” as shown in FIG. 5B.

According to an exemplary embodiment, the second rectangular lowercomponent 504 includes a second lower socket casing 546 located betweenthe first lower pocket 542 and a first edge 548 of the secondrectangular lower component 504, where the first edge 548 extends in thedirection of the fourth thickness “T3”. The second lower socket casing546 is defined by an indentation in the lower front wall 532, where theindentation has a second depth “D2”. In an embodiment, the second lowersocket casing 546 defines an opening 550 configured to receive anelectrical connection ribbon of an adjacent solar panel module 102.

The second rectangular lower component 504 also includes a second lowerplug casing 552 located between the second lower pocket 544 and a secondedge 554 of the second rectangular lower component 504. The second edge554 is parallel to the first edge 548 and the second lower plug casing552 extends for a second length “L2” from the lower front wall 532 indirection of the fourth thickness “T3”. In an embodiment, the seconddepth “D2” of the second lower socket casing 546 is equal to the secondlength “L2” of the second lower plug casing 552.

The second rectangular upper component 502 is configured to removablycouple with the second rectangular lower component 504 to constitute thesecond coupling module 210 (as can be seen in FIG. 3). Further, thesecond coupling module 210 includes a third magnet 556 and a fourthmagnet 558. Each of the third magnet 556 and the fourth magnet 558 has amagnet width equal to the pocket width, a magnet depth thickness to thepocket breadth and a magnet height equal to twice the pocket height.Owing to such dimensions of the magnets and the pockets, the thirdmagnet 556 is configured to be rigidly inserted into the first lowerpocket 542 such that a portion of the third magnet 556 lies outside thefirst lower pocket 542, and the fourth magnet 558 is configured to berigidly inserted into the second lower pocket 544 such that a portion ofthe fourth magnet 558 lies outside the second lower pocket 544. Theportion of the third magnet 556 extending outside the first lower pocket542 is configured to be received within the first upper pocket 522 andthe portion of the fourth magnet 558 extending outside the second lowerpocket 544 is configured to be received within the second upper pocket524 when the second rectangular upper component 502 is coupled to thesecond rectangular lower component 504. Such arrangement of the magnetsand the pockets serves to hold the second rectangular upper component502 and the second rectangular lower component 504 firmly together andhelps align the upper and lower components Further, in the coupledstate, the third slot 520 and the fourth slot 540 together defines thesecond cavity 306 (also referred to as second interior cavity in thepresent disclosure) configured to removably receive the second end 308of the solar cell assembly 200.

In an embodiment, each of the third magnet 556 and the fourth magnet 558may be neodymium magnet. In an embodiment, the third magnet 556 may havea negative polarity and the fourth magnet 558 may have a positivepolarity with respect to the upper front wall 512 of the second couplingmodule 210. It will be apparent to the person skilled in the art thatthe embodiments described with respect to the first magnet 446 and thesecond magnet 448 in FIG. 4B may be implemented to the secondrectangular lower component 504.

In a coupled state of the second rectangular upper component 502 and thesecond rectangular lower component 504, the first upper protrusion 514aligns and abuts with the first lower protrusion 534 to define a secondpin 360 (see FIG. 3). The second upper protrusion 516 aligns and abutswith the second lower protrusion 536 to define a third pin 362 (see FIG.3). The upper cut out 518 aligns with the lower cut out 538 to define athird notch 364 (see FIG. 3). In an embodiment, the second pin 360, thethird pin 362, and the third notch 364 together constitutes the secondpin joint 218 (see FIG. 2B).

In an embodiment, each component of the first coupling module 208 andthe second coupling module 210 of the first solar panel module 102-1 maybe 3D printed from a plastic selected from the group comprisingpolyaryletherketone, polyetherimide, polyether ether ketone ketone andpolyether ether ketone, preferably polyether ether ketone. In someembodiments, the 3D printing may be performed using resins,thermoplastics, polycarbonate, carbon fibers, gas-filled polymers,acrylonitrile styrene acrylate (ASA), engineering plastic, or acombination of one or more thereof, or any other material known to aperson skilled in the art.

Accordingly, construction of the first solar panel module 102-1 isdescribed. Each solar panel module 102 of the modular solar panel 100 isidentical in construction to the first solar panel module 102-1. Forexample, referring to FIG. 2A and FIG. 2B, the third coupling module 212of the second solar panel module 102-2 is identical to the firstcoupling module 208 of the first solar panel module 102-1, and thefourth coupling module 214 of the second solar panel module 102-2 isidentical to the second coupling module 210 of the first solar panelmodule 102-1. As such, the first pin joint 220 of the third couplingmodule 212 of the second solar panel module 102-2 is configured tointerlock with the second pin joint 218 of the second coupling module210 of the first solar panel module 102-1.

FIG. 5C illustrates a schematic cross-sectional view of the interlockbetween the first solar panel module 102-1 and the second solar panelmodule 102-2 as shown from the interior of two lower components. In anembodiment, the third magnet 556 may have the negative polarity and thefourth magnet 558 may have the positive polarity. The first magnet 446of the third coupling module 212 of the second solar panel module 102-2may have a positive polarity and the second magnet 448 may have anegative polarity. As such, when the third coupling module 212 of thesecond solar panel module 102-2 is located in proximity to the secondcoupling module 210 of the first solar panel module 102-1, the secondrectangular lower component 504 aligns with the first rectangular lowercomponent 404 owing to the attracting polarities of the magnets. Assuch, the alignment of the solar panel module 102 may be quicklyachieved without investing additional manual effort. Such alignment ofthe solar panel modules 102 also helps to achieve the interlock betweenthe solar panel modules 102.

In an embodiment, each coupling module of the solar panel modules 102includes an electrical connection port 566 configured to receive one ofthe first electrical connection ribbon 314 and the second electricalconnection ribbon 318. In an embodiment, a first electrical connectionport 566-1 of the first coupling module 208 is configured toelectrically connect to a second electrical connection port 566-2 of thesecond coupling module 210.

According to an exemplary embodiment, an electrical plug 568 is formedby connecting the first lower plug casing 454 of the third couplingmodule 212 of the second solar panel module 102-2 with the second lowersocket casing 546 of the second coupling module 210 of the first solarpanel module 102-1. Similarly, an electrical socket 570 is formed byconnecting the first lower socket casing 450 with the second lower plugcasing 552. The electrical socket 570 and the electrical plug 568 allowsextraction of electrical power from the modular solar panel 100.

FIG. 6A illustrates a flowchart of a method 600 for assembling themodular solar panel 100, according to certain embodiments of the presentdisclosure. The method 600 will be described in conjunction with theFIG. 1 through FIG. 5C. The method 600 is directed towards forming thefirst solar panel module 102-1. At step 602, the method 600 includesforming the first solar cell assembly 200 by sandwiching the first solarcell array 206 between the first protective glass 202 and the first baseplate 204, so that the first electrical connection ribbon 314 extendsfrom the first end 316 of the first solar cell array 206, and the secondelectrical connection ribbon 318 extends from the second end 320, whichis opposite to the first end 316, of the first solar cell array 206.

At step 604, the method 600 includes joining the first rectangular uppercomponent 402 to the first rectangular lower component 404 to form thefirst coupling module 208 having the first interior cavity 302, thefirst electrical connection port 566-1, a first electrical connectionsocket and the first pin joint 216 having one pin and two notches.

At step 606, the method 600 includes joining the second rectangularupper component 502 to the second rectangular lower component 504 toform the second coupling module 210 having the second interior cavity306, the second electrical connection port 566-2, a second electricalconnection socket and the second pin joint 218 having two pins and onenotch.

At step 608, the method 600 includes inserting the first end 304 of thefirst solar cell assembly 200 into the first interior cavity 302 of thefirst coupling module 208 while guiding the first electrical connectionribbon 314 into the first electrical connection port 566-1.

At step 610, the method 600 includes inserting the second end 308 of thefirst solar cell assembly 200 into the second interior cavity 306 of thesecond coupling module 210 while guiding the second electricalconnection ribbon 318 into the second electrical connection socket.

Although not illustrated through steps in FIG. 6A, the method 600further includes joining the first rectangular upper component 402 tothe first rectangular lower component 404. This is performed byinserting a first portion of the first magnet 446 in the first upperpocket 434 and a first portion of the second magnet 448 into the secondupper pocket 436 of the first rectangular upper component 402 of thefirst coupling module 208, 212. The method 600 further includesinserting a second portion of the first magnet 446 into the first lowerpocket 438 and a second portion of the second magnet 448 into the secondlower pocket 440 of the first rectangular lower component 402 of thefirst coupling module 208, 212.

The method 600 further includes joining the second rectangular uppercomponent 502 to the second rectangular lower component 504. This isperformed by inserting a third portion of the third magnet 556 into thethird upper pocket 522 and a fourth portion of the fourth magnet 558into a fourth upper pocket 436 of the second rectangular upper component502 of a third coupling module. The method 600 further includesinserting a third portion of the third magnet 556 into a third lowerpocket 438 and a fourth portion of the fourth magnet 558 into a fourthlower pocket 440 of the second rectangular lower component 504 of thethird coupling module.

FIG. 6B is a flowchart of a method 650 for assembling the modular solarpanel 100 and forming the second solar panel module 102-2, according tocertain embodiments of the present disclosure. In an embodiment, thesecond solar panel module 102-2 is identical in construction to thefirst solar panel module 102-1. At step 652, the method 650 includesforming the second solar cell assembly 200 by sandwiching the secondsolar cell array between a second protective glass and a second baseplate, so that a third electrical connection ribbon extends from a firstend of the second solar cell array and a fourth electrical connectionribbon extends from a second, opposite end of the second solar cellarray.

At step 654, the method 650 includes joining a third rectangular uppercomponent to a third rectangular lower component to form a thirdcoupling module having a third interior cavity, a third electricalconnection port, a third electrical connection socket and a third pinjoint having two pins and one notch.

At step 656, the method 650 includes joining a fourth rectangular uppercomponent to a fourth rectangular lower component to form a fourthcoupling module having a fourth interior cavity, a fourth electricalconnection port, a fourth electrical connection socket and a fourth pinjoint having one pin and two notches.

At step 656, the method 650 includes inserting the first end of thesecond solar cell assembly into the third interior cavity of the thirdcoupling module while guiding the third electrical connection ribboninto the third electrical connection port.

At step 660, the method 650 includes inserting the second end of thesecond solar cell assembly into a fourth interior cavity of a fourthcoupling module while guiding the fourth electrical connection ribboninto the fourth electrical connection port socket.

Although not illustrated through steps in FIG. 6B, the method 650further includes joining the third rectangular upper component to thethird rectangular lower component. This is performed by inserting afirst portion of a fifth magnet into a fifth upper pocket and a firstportion of a sixth magnet into a sixth upper pocket of the thirdrectangular upper component of the third coupling module. The method 650also includes inserting a second portion of the fifth magnet into afifth lower pocket and a second portion of the sixth magnet into a sixthlower pocket of the third rectangular lower component of the thirdcoupling module.

The method 650 also includes joining the fourth rectangular uppercomponent to the fourth rectangular lower component. This is performedby inserting a first portion of a seventh magnet into a seventh upperpocket and a first portion of an eighth magnet into an eighth upperpocket of the fourth rectangular upper component of the fourth couplingmodule. The method 650 also includes inserting a second portion of theseventh magnet into a seventh lower pocket and a second portion of theeighth magnet into an eighth lower pocket of the fourth rectangularlower component of the fourth coupling module.

The method 650 further includes inserting the first magnet into thefirst upper pocket of the first upper component with a positive polaritytowards a first upper front wall.

The method 650 further includes inserting the second magnet into thesecond upper pocket of the first upper component with a negativepolarity towards the first upper front wall.

The method 650 further includes inserting the third magnet into thethird upper pocket of the second upper component with a positivepolarity towards a second upper front wall.

The method 650 further includes inserting the fourth magnet into thefourth upper pocket of the second upper component with a negativepolarity towards the second upper front wall.

The method 650 further includes inserting the fifth magnet into thefirst upper pocket of the third upper component with a positive polaritytowards a third upper front wall.

The method 650 further includes inserting the sixth magnet into thesecond upper pocket of the third upper component with a negativepolarity towards the third upper front wall.

The method 650 further includes inserting the seventh magnet into thefirst upper pocket of the fourth upper component with a positivepolarity towards a fourth upper front wall.

The method 650 further includes inserting the eighth magnet into thesecond upper pocket of the fourth upper component with a negativepolarity towards the fourth upper front wall.

FIG. 6C is a flowchart of a method 690 for assembling the modular solarpanel 100 with the first solar panel module and the second solar panelmodule. At step 692, the method 690 includes connecting the first solarpanel module 102-1 to the second solar panel module 102-2 by insertingthe first pin joint 216 into the fourth pin joint, the first electricalconnection port into the fourth electrical connection socket and thefirst electrical connection socket into the fourth electrical connectionport.

At step 694, the method 690 includes aligning the first solar panelmodule 102-1 with the second solar panel module 102-2 by magneticallycontacting the first magnet 446 of the first coupling module 210 to thefourth magnet of a second coupling module and magnetically contactingthe second magnet of the first coupling module to the third magnet ofthe second coupling module.

Obviously, numerous modifications and variations of the presentdisclosure are possible in light of the above teachings. It is thereforeto be understood that within the scope of the appended claims, theinvention may be practiced otherwise than as specifically describedherein.

1. A modular solar panel, comprising: a plurality of solar panelmodules, each solar panel module including: a plurality of solar cellassemblies, each solar cell assembly including a protective glass; abase plate; a solar cell array located between the protective glass andthe base plate; and a first electrical connection ribbon extending froma first end of the solar cell array and a second electrical connectionribbon extending from a second end of the solar cell array; a pluralityof coupling modules, each coupling module including an interior cavityconfigured to receive an end of a solar cell assembly; a pin jointlocated on an exterior of the coupling module, wherein the pin joint ofa first coupling module is configured to interlock with the pin joint ofa second coupling module; and an electrical connection port configuredto receive one of the first and the second electrical connectionribbons, wherein the electrical connection port of the first couplingmodule is configured to electrically connect to the electricalconnection port of the second coupling module.
 2. The modular solarpanel of claim 1, wherein each coupling module further comprises: arectangular upper component having a first perimeter and a first planarsurface, a first upper sidewall, a second upper sidewall and an upperfront wall having a first thickness, wherein the first upper sidewall,the second upper sidewall and the upper front wall extendperpendicularly from the first planar surface at the first perimeter; arectangular lower component having a second perimeter and a secondplanar surface, a first lower sidewall, a second lower sidewall and alower front wall having the first thickness, wherein the first lowersidewall, the second lower sidewall and the lower front wall extendperpendicularly from the second planar surface at the second perimeter;and a first interior cavity formed when the rectangular upper componentis joined to the rectangular lower component so that the upper frontwall aligns with the lower front wall, the first lower sidewall alignswith the first lower sidewall, and the second upper sidewall aligns withthe second lower sidewall.
 3. The modular solar panel of claim 2,wherein the upper and lower components are 3D printed from a plasticselected from the group comprising polyaryletherketone, polyetherimide,polyether ether ketone ketone and polyether ether ketone, preferablypolyether ether ketone.
 4. The modular solar panel of claim 2, whereineach coupling module further comprises: at least one upper protrusionand at least one upper cut out centrally located on an exterior of theupper front wall and extending in a direction of the first thickness; atleast one lower protrusion and at least one lower cut out centrallylocated on an exterior of the lower front wall and extending in adirection of the second thickness; wherein each upper protrusion definesa pin when aligned with a lower protrusion; wherein each upper cut outdefines a notch when aligned with a lower cut out; and wherein the pinjoint comprises at least one pin and at least one notch.
 5. The modularsolar panel of claim 4, wherein each coupling module further comprises:a first upper pocket and a second upper pocket located in the firstthickness to either side of the at least one upper protrusion and atleast one upper cut out; a first lower pocket and a second lower pocketlocated in the second thickness to either side of the at least one lowerprotrusion and at least one lower cut out; wherein each first upperpocket, second upper pocket, first lower pocket and second lower pockethas equal width, equal depth and equal height; a first magnet and asecond magnet, each having the equal width, the equal depth and twicethe equal height; wherein insertion of the first magnet into the firstupper pocket and into a corresponding first lower pocket and insertionof the second magnet into the second upper pocket and into acorresponding second lower pocket holds the first rectangular uppercomponent and the second rectangular lower component together.
 6. Themodular solar panel of claim 5, wherein: each magnet is a neodymiummagnet; the first magnet has a positive polarity, and the second magnethas a negative polarity with respect to the upper front wall of thefirst coupling module.
 7. The modular solar panel of claim 5, whereineach pocket is located within 0.1 cm to 0.5 cm of an exterior surface ofthe upper front wall of a respective coupling module.
 8. The modularsolar panel of claim 5, wherein each upper component further comprises:an upper plug casing located between the first upper pocket and a firstedge of the upper component, the first edge lying in the direction ofthe first thickness, wherein the upper plug casing extends for a firstlength from the upper front wall in the thickness direction; and aribbon channel which extends from the first interior cavity through theupper plug casing.
 9. The modular solar panel of claim 8, wherein eachlower component further comprises: a lower plug casing located betweenthe first lower pocket and a first edge of the lower component, thefirst edge of the lower component lying in the direction of the secondthickness, wherein the lower plug casing extends for the first lengthfrom the lower front wall in the second thickness direction; a lowersocket casing located between the second lower pocket and a second edgeof the lower component parallel to the first edge of the lowercomponent, wherein the lower socket casing is defined by an indentationin the lower front wall, wherein the indentation has a depth equal tothe first length.
 10. The modular solar panel of claim 4, furthercomprising: a first pin joint configuration which includes two notchesand one pin; a second pin joint configuration which includes one notchand two pins; and wherein a first coupling module having the first pinjoint configuration is configured to interlock with a second couplingmodule having the second pin joint configuration.
 11. The modular solarpanel of claim 10, further comprising: a first solar panel module havingthe first pin joint configuration installed on a first end and thesecond pin joint configuration installed on a second end; a second solarpanel module having the first pin configuration installed on a third endand the second pin joint configuration installed on a fourth end; andwherein the first pin joint configuration of the first solar panelmodule is configured to interlock with the second pin joint of thesecond solar panel module.
 12. The modular solar panel of claim 1, thesolar cell array further comprising: a plurality of rows of solar cells;a metal interconnect layer configured to electrically connect theplurality of rows of solar cells in a series and in a parallel circuithaving an input at the first electrical connection ribbon and an outputat the second electrical connection ribbon.
 13. The modular solar panelof claim 1, wherein: the protective glass is transparent; and the baseplate is one of plastic and synthetic polymer.
 14. A method forassembling a modular solar panel, comprising: forming a first solarpanel module by: forming a first solar cell assembly by sandwiching afirst solar cell array between a first protective glass and a first baseplate, so that a first electrical connection ribbon extends from a firstend of the first solar cell array and a second electrical connectionribbon extends from a second, opposite end of the first solar cellarray; joining a first rectangular upper component to a firstrectangular lower component to form a first coupling module having afirst interior cavity, a first electrical connection plug, a firstelectrical connection socket and a first pin joint having two pins andone notch; joining a second rectangular upper component to a secondrectangular lower component to form a second coupling module having asecond interior cavity, a second electrical connection plug, a secondelectrical connection socket and a second pin joint having one pin andtwo notches; inserting the first end of the first solar cell assemblyinto the first interior cavity of the first coupling module whileguiding the first electrical connection ribbon into the first electricalconnection port; and inserting the second end of the first solar cellassembly into the second interior cavity of the second coupling modulewhile guiding the second electrical connection ribbon into the secondelectrical connection socket.
 15. The method of claim 14, furthercomprising: joining the first rectangular upper component to the firstrectangular lower component by: inserting a first portion of a firstmagnet in a first upper pocket and a first portion of a second magnetinto a second upper pocket of the first rectangular upper component ofthe first coupling module; inserting a second portion of the firstmagnet into a first lower pocket and a second portion of the secondmagnet into a second lower pocket of the first rectangular lowercomponent of the first coupling module; joining the second rectangularupper component to the second rectangular lower component by: insertinga third portion of a third magnet into a third upper pocket and a fourthportion of a fourth magnet into a fourth upper pocket of a secondrectangular upper component of a third coupling module; and inserting athird portion of the third magnet into a third lower pocket and a fourthportion of the fourth magnet into a fourth lower pocket of the secondrectangular lower component of the third coupling module.
 16. The methodof claim 15, further comprising: forming a second solar panel module by:forming a second solar cell assembly by sandwiching a second solar cellarray between a second protective glass and a second base plate, so thata third electrical connection ribbon extends from a first end of thesecond solar cell array and a fourth electrical connection ribbonextends from a second, opposite end of the second solar cell array;joining a third rectangular upper component to a third rectangular lowercomponent to form a third coupling module having a third interiorcavity, a third electrical connection port, a third electricalconnection socket and a third pin joint having two pins and one notch;joining a fourth rectangular upper component to a fourth rectangularlower component to form a fourth coupling module having a fourthinterior cavity, a fourth electrical connection port, a fourthelectrical connection socket and a fourth pin joint having one pin andtwo notches; inserting the first end of the second solar cell assemblyinto the third interior cavity of the third coupling module whileguiding the third electrical connection ribbon into the third electricalconnection port; and inserting the second end of the second solar cellassembly into a fourth interior cavity of a fourth coupling module whileguiding the fourth electrical connection ribbon into the fourthelectrical connection port socket.
 17. The method of claim 16, furthercomprising: joining the third rectangular upper component to the thirdrectangular lower component by: inserting a first portion of a fifthmagnet into a fifth upper pocket and a first portion of a sixth magnetinto a sixth upper pocket of the third rectangular upper component ofthe third coupling module; inserting a second portion of the fifthmagnet into a fifth lower pocket and a second portion of the sixthmagnet into a sixth lower pocket of the third rectangular lowercomponent of the third coupling module; joining the fourth rectangularupper component to the fourth rectangular lower component by: insertinga first portion of a seventh magnet into a seventh upper pocket and afirst portion of an eighth magnet into an eighth upper pocket of thefourth rectangular upper component of the fourth coupling module; andinserting a second portion of the seventh magnet into a seventh lowerpocket and a second portion of the eighth magnet into an eighth lowerpocket of the fourth rectangular lower component of the fourth couplingmodule.
 18. The method of claim 17, further comprising: inserting thefirst magnet into the first upper pocket of the first upper componentwith a positive polarity towards a first upper front wall; inserting thesecond magnet into the second upper pocket of the first upper componentwith a negative polarity towards the first upper front wall; andinserting the third magnet into the third upper pocket of the secondupper component with a positive polarity towards a second upper frontwall; inserting the fourth magnet into the fourth upper pocket of thesecond upper component with a negative polarity towards the second upperfront wall; inserting the fifth magnet into the first upper pocket ofthe third upper component with a positive polarity towards a third upperfront wall; inserting the sixth magnet into the second upper pocket ofthe third upper component with a negative polarity towards the thirdupper front wall; and inserting the seventh magnet into the first upperpocket of the fourth upper component with a positive polarity towards afourth upper front wall; and inserting the eighth magnet into the secondupper pocket of the fourth upper component with a negative polaritytowards the fourth upper front wall.
 19. The method of claim 18, furthercomprising: connecting the first solar panel module to the second solarpanel module by inserting the first pin joint into the fourth pin joint,the first electrical connection port into the fourth electricalconnection socket and the first electrical connection socket into thefourth electrical connection port; and aligning the first solar panelmodule with the second solar panel module by magnetically contacting thefirst magnet of the first coupling module to the fourth magnet of asecond coupling module and magnetically contacting the second magnet ofthe first coupling module to the third magnet of the second couplingmodule.
 20. A method for assembling a modular solar panel, comprising:forming a plurality of solar panel modules, by: forming a plurality ofsolar cell assemblies; forming a plurality of coupling modules, eachcoupling module including an electrical plug at a first end, anelectrical socket at a second end, a pin joint, a first magnet having afirst polarity located between the electrical plug and the pin joint, asecond magnet having a second polarity located between the electricalsocket and the pin joint, and an interior cavity; inserting a first endof each of the solar cell assemblies into a first coupling module havinga pin joint configuration including two pins and a notch; inserting asecond end of each of the solar cell assemblies into a second couplingmodule having a pin joint configuration including one pin and twonotches; and joining a first solar panel module to a second solar panelmodule by interlocking the two pins and the notch of the first solarpanel module into the one pin and two notches of the second solar panelmodule, inserting the electrical plug of the first solar panel moduleinto the electrical socket of the second solar panel module, whilemagnetically aligning the first solar panel module with the second solarpanel module.